Molded paper pulp pizza box

ABSTRACT

An apparatus for containing a hot food product for delivery. The apparatus comprises a box member formed of molded paper pulp having a first predetermined shape and a first predetermined size. The box member has a base portion and a wall portion each of the base portion and the wall portion have an interior surface and an exterior surface. A plurality of raised portions having a second predetermined shape are disposed on the interior surface of the base portion. Such raised portions cover greater than 50 per cent of the interior surface of the base portion of the box member. A molded paper pulp lid member is engageable with the box member. The lid member has a second predetermined shape and a second predetermined size and has both an interior surface and an exterior surface. There is at least one closure means having a first portion formed on the lid member and a second portion formed on the box member for closing such box after such hot food product is placed therein.

FIELD OF THE INVENTION

The present invention relates, in general, to a pizza box, and, moreparticularly, the present invention relates to a pizza box that is madeof molded paper pulp.

BACKGROUND OF THE INVENTION

Corrugated paper material that is currently used for pizza deliveryboxes tends to become soggy and to lose some of its structural strengthafter absorbing greasy drippings and steam condensation. A corrugatedbox also absorbs moisture emanating from hot, steaming pizza as itemerges from the oven. As a result, the top portion begins to droop abit and some retailers use a small plastic piece on top of the pizza tohold the top up so that it does not touch the pizza toppings. Most pizzathat is made available through retailers are circular in shape yet thepizza its transported in a square shaped box because of limitations ofthe die-cut corrugated paper box-making process. This mismatch in shapeintroduces unnecessary air around the hot product that leads toadditional heat loss. Moreover, the mismatch allows the pizza to slidearound in the box which can lead to loss of toppings and a messy pizzaand box.

It should be noted that molded paper in environmentally responsible.Molded paper packaging is made from 100% recycled paper and a result isitself entirely recyclable and compostable. It can also be made fromeasy to renew resources like sugarcane pulp, weed pulp and wood chippulp. Companies with a commitment to environmental issues show theirsupport by packaging in molded paper. Molded paper also complies withthe rigorous European Community packaging directive which mandatesrecycled packaging content.

A typical twelve inch corrugated paper box that is currently used inpizza deliveries cost the pizza retailer 35 to 40 cents at a bulk rate.A molded paper pulp pizza delivery box could be made for 30 to 50% less.In addition, cost for the raw materials for molded paper pulp productsare generally more stable compared to corrugated paperboard or EPS.Further, using a circular delivery box creates a more secure packagingwith less heat loss.

Thus, it would be advantageous if there were a pizza delivery boxavailable that was made of molded paper pulp that would not is only becheaper to produce but could be made in a circular form that would bemore conducive for the delivery of a round pizza and also be packaged ina box that is not only made of recycled paper but is in itself entirelyrecyclable.

SUMMARY OF THE INVENTION

In a first aspect the present invention provides an apparatus forcontaining a hot food product for delivery. The apparatus comprises abox member formed of molded paper pulp having a first predeterminedshape and a first predetermined size. The box member has a base portionand a wall portion each of the base portion and the wall portion have aninterior surface and an exterior surface. A plurality of raised portionshaving a second predetermined shape are disposed on the interior surfaceof the base portion. Such raised portions cover greater than 50 per centof the interior surface of the base portion of the box member. A moldedpaper pulp lid member is engageable with the box member. The lid memberhas a second predetermined shape and a second predetermined size and hasboth an interior surface and an exterior surface. There is at least oneclosure means having a first portion formed on the lid member and asecond portion formed on the box member for closing such box after suchhot food product is placed therein.

OBJECTS OF THE INVENTION

It is, therefore, one of the primary objects of the present invention toprovide a pizza delivery box that is made of molded paper pulp.

Another object of the present invention is to provide a pizza deliverybox that is made in a circular form.

Still another object of the present invention is to provide a pizzadelivery box that is cheaper to make than present corrugated paperboxes.

Yet another object of the present invention is to provide a pizzadelivery box that has excellent heat insulation.

Another object of the present invention is to provide a pizza deliverybox that is far superior in handling greasy, oily products such as pizzathan is the present corrugated paper boxes.

Still another object of the present invention is to provide a pizzadelivery box that has better stackability than currently used boxes.

Yet another object of the present invention is to provide a pizzadelivery box that does not require assembling.

Another object of the present invention is to provide a pizza deliverybox that has an embossed design.

In addition to the various objects and advantages of the invention whichhave been described in some specific detail above it should be notedthat various other objects and advantages of the present invention willbecome more readily apparent to those persons who are skilled in therelevant art from the following more detailed description, particularlywhen such description is taken in conjunction with the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of the top of a pizza delivery box anda lid according to an embodiment of the invention.

FIG. 2 is a is a perspective view of the bottom of a pizza delivery box.

FIG. 3 is a cross section of the lid member shown in FIG. 1 taken acrossthe line III-III.

FIG. 4 is a cross section of the box member shown in FIG. 1 taken acrossthe line IV-IV.

FIG. 5 is a top perspective view of the top of a pizza delivery boxshowing the lid connected to the base portion of the box.

FIGS. 6A and 6B are perspective views of the pizza delivery box showingone means of closure.

FIGS. 7A and 7B are perspective views of the pizza delivery box showingan alternate closure means.

BRIEF DESCRIPTION OF THE PRESENTLY PREFERRED AND VARIOUS ALTERNATIVEEMBODIMENTS OF THE INVENTION

Prior to proceeding with the more detailed description of the presentinvention it should be noted that, for the sake of clarity, identicalcomponents which have identical functions have been designated byidentical reference numerals throughout the several views illustrated inthe drawings.

In a first aspect the present invention provides an apparatus, generallydesignated 10, for containing a hot food product for delivery. It iswithin the scope of the invention that the apparatus 10 could be usedfor transporting various hot food products; however, the main hot foodproduct that the invention is designed for is for the delivery of pizza,since pizza is by far the product that is most widely thought of whenone thinks of home delivery. The apparatus 10 comprises a box member 2formed of molded paper pulp and having a first predetermined shape and afirst predetermined size. The box member 2 has a base portion 4 and awall portion 6, each of the base portion 4 and the wall portion 6 havean interior surface and an exterior surface.

A plurality of raised portions 8 having a second predetermined shape aredisposed on the interior surface of the base portion 4. Such raisedportions 8 cover greater than 50 per cent of the interior surface of thebase portion 4 of the box member 2. A molded paper pulp lid member 12 isengageable with the box member 2. The lid member 12 has a secondpredetermined shape and a second predetermined size and has both aninterior surface and an exterior surface. Such lid member 12 when placedon top of the box member 2 has a substantially flat top surface 13 and adownwardly extending wall portion 15.

There is at least one closure means, generally designated 20, having afirst portion formed on the lid member 12 and a second portion formed onthe box member 2 for closing such box 2 after such hot food product isplaced therein.

Such box member 2 and such lid member 12 can be formed as separateentities; however, in a presently preferred embodiment of the inventionsuch molded paper pulp lid member 12 is hingedly connected along oneedge thereof to a corresponding edge of said box member 2. Having thelid member 12 and the box member 2 formed as a single unit means thatthere will not have to be any assembly after the box is filled, onesimply has to fold over the lid member and close it on top of the boxmember 2 and the apparatus 10 is ready for delivery. Further, having thelid member 12 attached to the box member 2 makes it easy to stack theunits one on top of another which takes up a minimum amount of space.

Outer portions of each of the plurality of raised portions 8 aredisposed a predetermined distance away from an outer periphery of theinterior surface of the base member 4 of box member 2. It is alsopresently preferred that the plurality of raised portions 8 be uniformlydisposed on the interior surface of the box member 2. It is alsopresently preferred that such plurality of raised portions 8 besubstantially triangular in shape.

The outer surface of the box member 2 has raised portions 14, theseraised portions 14 correspond to the area 16 between the outer peripheryof the interior surface of the box member 2 and the outer portion of theplurality of raised portions 8 and further correspond to the area 18between each uniformly disposed raised portion 8 on the interior surfaceof the box member 2. Such raised portions 14 on the outer surface of thebox member 2 are designed for creating air pockets between the boxmember 2 and a supporting surface.

Such first predetermined shape of such box member can be one ofsubstantially circular, hexagonal, octagonal and rectangular. It ispresently preferred that such first predetermined shape is substantiallycircular primarily because the apparatus 10 is designed for the deliveryof pizza and the circular shape would correspond to the common shape ofpizzas. With the circular shape there is next to no wasted space in theapparatus and thereby there is less chance of the pizza sliding aroundin the container as can be the case with a rectangular box. Further, thefirst predetermined size would be the size of the pizza to be containedtherein. That is, the box would be a size sufficient to contain a 12inch pizza or there could be a smaller box for the delivery of a 9 inchpizza and so on.

Such apparatus 10 further can include a thin laminating film 22 that isdisposed on at least the interior surface of the box member 2 and thelid member 12. Such laminating film 22 could also be disposed on theexterior surface of the box member 2 and the lid member 12.

As more clearly seen in FIG. 4 in cross section, the wall portions 6 ofbox member 2 further include a ridge member 24. The ridge member 24extends outwardly from the wall portion 6. Similarly, as seen in FIG. 3,the lid member 12 includes a ridge member 26 that extends outwardly fromthe wall portion 15 of the lid member. The ridge member 24 on the boxmember 2 mates with the corresponding ridge member 26 on the lid member12.

The closure means 20 includes a groove 28 that is disposed on an uppersurface of the ridge member 24 and extends an entire perimeter of theridge member 24. The closure means 20 also includes a rounded projection32 disposed on a lower surface of the lid member 12 and extends theentire perimeter of the ridge member 26 for engagement with the groove28 disposed on ridge member 24 of the wall portion 6 of the box member 2for securing the lid member 12 to the box member 2 thereby reducing anyheat loss when transporting such pizza.

The ridge member 24 of the box member further includes a lip portion 34disposed on an outer periphery of the ridge member 24, such lip portion34 is disposed on an outer edge of the groove 28. Similarly the ridgemember 26 of the lid member 12 further includes a lip portion 36disposed on the outer periphery of the ridge member 26 of the lip member12. The lip portion 36 is disposed on an outer edge of the projection32, such lip portion 36 of the lid member 12 is engageable with the lipportion 34 of the ridge member 24 of the wall portion 6 of the boxmember 2.

The ridge member ridge member 24 on the box member 2 further includes aprojection 42 that extends outwardly therefrom. The projection 42 isdisposed on a radially opposed portion of the boxmember 2 from theportion of the box member 2 where the hingedly connected lid member 12is attached. The projection 42 on the box member includes at least oneslit 46 disposed in the projection 42.

Similarly, the ridge member 26 of the lid member 12 further includes aprojection 44 that extends outwardly therefrom. This projection 44engages the at least one slit 46 in the projection 42 on the box member2.

In an alternate embodiment, as seen in FIGS. 1, 7A and 7B, suchprojection 42 on the box member 2 includes two slits 46 disposed in theprojection 42. The two slits 46 are spaced equidistant on the projection42. To correspond to the two slits 46 in this embodiment such projection44 on the lid member 12 includes two separate projections 44 forengagement with the two slits 46 disposed on the box member 2.

Thus, the present invention provides a pizza delivery box 10 is that ismade of molded paper. Such molded paper uses the latest advances in foodgrade molded pulp technology to significantly improve the way pizza ispresented and transported for delivery. The invention capitalizes onadvances in molded paper pulp technology whereby food-grade packagingcan now be developed from 100% post-consumption paper pulp. Compared tocurrently used corrugated paper boxes the innovation appreciably reducesthe per-piece cost of packaging, while delivering a product withexcellent heat insulation, moisture absorption and structural strength.Such a product is actually far superior in handling greasy, oilyproducts like pizza. Additionally the “molded” nature of packagingallows distinct branding opportunities like “molded-in-logos” orattractive design patterns making the product a good vehicle to pushbrand distinction.

The pulp-molding process is a very low cost manufacturing process andafter use, the material is 100% biodegradable. The round die-cutcorrugated boxes are transported as flat shapes and must be assembledprior to use in delivery. The new design will reduce the effort requiredand the time needed. The molded paper pulp forms stack up exceptionallywell (with minimal empty space between packaging), thereby using lessspace at the delivery counter compared to assembled corrugated boxesthat do not stack well and retain empty interior space. Using thecircular delivery box will also create a more secure and betterheat-retaining packaging. Other attractive and optimal shapes and formsmay be produced according to manufacturer specifications.

The structural elements of the lid of the molded paper pulp delivery boxdesign allow for placement of an outer branding sticker and will alsoprovide physical strength to the most vulnerable area of the lid. Themolded box features raised surfaces or slices that create air pocketsbetween the hot, oven-baked pizza box and the supporting surface (like atable) below, thereby reducing the rate of heat loss. A molded-in hinge,seal or flap that provides safe and secure closure to the box can jointhe upper and lower box portions yet various options are available tooffer proper sealing and thus prevent heat loss.

While a presently preferred embodiment and alternate embodiments of thepresent invention have been described in detail above, it should beunderstood that various other adaptations and/or modifications of theinvention can be made by those persons who are particularly skilled inthe art without departing from either the spirit of the invention or thescope of the appended claims.

1. An apparatus for containing a hot food product for delivery, saidapparatus comprising; (a) a box member formed of molded paper pulphaving a first predetermined shape and a first predetermined size, saidbox member having a base portion and a wall portion each of said baseportion and said wall portion having an interior surface and an exteriorsurface; (b) a plurality of raised portions having a secondpredetermined shape disposed on said interior surface of said baseportion, said raised portions covering greater than 50 per cent of saidinterior surface of said base portion of said box member; (c) a moldedpaper pulp lid member engageable with said box member, said lid memberhaving a second predetermined shape and a second predetermined size andhaving a substantially flat top portion and a wall portion each of saidsubstantially flat top portion and said wall portion having an interiorsurface and an exterior surface; and (d) at least one closure meanshaving a first portion formed on said lid member and a second portionformed on said box member for closing said box after such pizza isplaced therein.
 2. The apparatus, according to claim 1, wherein saidmolded paper pulp lid member is hingedly connected along one edgethereof to a corresponding edge of said box member.
 3. The apparatus,according to claim 1, wherein outer portions of each said plurality ofraised portions are disposed a predetermined distance away from an outerperiphery of said interior surface of said base member of box member. 4.The apparatus, according to claim 3, wherein said plurality of raisedportions are uniformly disposed on said interior surface of said boxmember.
 5. The apparatus, according to claim 4, wherein said outersurface of said box member has raised portions, said raised portionscorresponding to an area between said outer periphery of said interiorsurface of said box member and said outer portion of said plurality ofraised portions and further corresponding to an area between eachuniformly disposed raised portion on said interior surface of said boxmember, said raised portions on said outer surface of said box memberfor creating air pockets between said box member and a supportingsurface.
 6. The apparatus, according to claim 1, wherein said firstpredetermined shape is one of substantially circular, hexagonal,octagonal and rectangular.
 7. The apparatus, according to claim 6,wherein said first predetermined shape is substantially circular.
 8. Theapparatus, according to claim 1, wherein said apparatus further includesa thin laminating film disposed on at least said interior surface ofsaid box member and said lid member.
 9. The apparatus, according toclaim 8, wherein said apparatus further includes said thin laminatingfilm disposed on said exterior surface of said box member and said lidmember.
 10. The apparatus, according to claim 2, wherein said wallportions of said box member further includes a ridge member, said ridgemember extending outwardly from said wall portion.
 11. The apparatus,according to claim 10, wherein said closure means includes a groovedisposed on an upper surface of said ridge member and extending anentire perimeter of said ridge member.
 12. The apparatus, according toclaim 11, wherein said lid member includes a ridge member extendingoutwardly from said wall portion of said lid member.
 13. The apparatus,according to claim 12, wherein said closure means includes a roundedprojection disposed on a lower surface of said ridge member of said lidmember and extending an entire perimeter of said ridge member forengagement with said groove disposed on said ridge member of said wallportion of said box member for securing said lid member to said boxmember thereby reducing any heat loss when transporting such pizza. 14.The apparatus, according to claim 13, wherein said ridge member of saidbox member further includes a lip member disposed on an outer peripheryof said ridge member, said lip member disposed on an outer edge of saidgroove.
 15. The apparatus, according to claim 14, wherein said ridgemember of said lid member further includes a lip member disposed on anouter periphery of said ridge member of said lip member, said lip memberis disposed on an outer edge of said rounded projection, said lip memberof said lid member engageable with said lip member of said ridge memberof said wall portion of said box member.
 16. The apparatus, according toclaim 10, wherein said ridge member further includes a projectionextending outwardly therefrom, said projection disposed on a radiallyopposed portion of said box member from said portion of said box memberwhere said hingedly connected lid member is attached.
 17. The apparatus,according to claim 16, wherein said projection on said box memberincludes at least one slit disposed in said projection.
 18. Theapparatus, according to claim 17, wherein said ridge member of said lidmember further includes a projection extending outwardly therefrom, saidprojection for engaging said at least one slit in said projection onsaid box member.
 19. The apparatus, according to claim 18, wherein saidprojection on said box member includes two slits disposed in saidprojection, said two slits being spaced equidistant on said projection.20. The apparatus, according to claim 19, wherein said projectiondisposed on said lid member includes two separate projections forengagement with said two slits disposed on said box member.
 21. Theapparatus, according to claim 1, wherein said lid member and said boxmember are separate units.
 22. The apparatus, according to claim 1,wherein said second predetermined shape of said raised portions aresubstantially triangular.